Articulated arm

ABSTRACT

An articulated arm CMM comprises a plurality of transfer members, a plurality of articulation members connecting at least two transfer members to each other, a coordinate acquisition member at a distal end, and a base at a proximal end. At least two of the articulation members can include at least one encoder and the at least two encoders can both be enclosed within a single monoblock housing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 12/748,169, entitled “ARTICULATED ARM”, and filedMar. 26, 2010, now issued as U.S. Pat. No. 8,112,896, which claims thepriority benefit under 35 U.S.C. §119(e) to U.S. Provisional PatentApplication Ser. No. 61/259,105 (filed Nov. 6, 2009), the entirety ofwhich is hereby expressly incorporated by reference herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to articulated arms and coordinatemeasurement, and more particularly to coordinate measurement machines.

2. Description of the Related Art

Rectilinear measuring systems, also referred to as coordinate measuringmachines (CMMs) and articulated arm measuring machines, are used togenerate highly accurate geometry information. In general, theseinstruments capture the structural characteristics of an object for usein quality control, electronic rendering and/or duplication. One exampleof a conventional apparatus used for coordinate data acquisition is aportable coordinate measuring machine (PCMM), which is a portable devicecapable of taking highly accurate measurements within a measuring sphereof the device. Such devices often include a probe mounted on an end ofan arm that includes a plurality of transfer members connected togetherby joints. The end of the arm opposite the probe is typically coupled toa moveable base. Typically, the joints are broken down into singularrotational degrees of freedom, each of which is measured using adedicated rotational transducer. During a measurement, the probe of thearm is moved manually by an operator to various points in themeasurement sphere. At each point, the position of each of the jointsmust be determined at a given instant in time. Accordingly, eachtransducer outputs an electrical signal that varies according to themovement of the joint in that degree of freedom. Typically, the probealso generates a signal. These position signals and the probe signal aretransferred through the arm to a recorder/analyzer. The position signalsare then used to determine the position of the probe within themeasurement sphere. See e.g., U.S. Pat. Nos. 5,829,148 and 7,174,651,which are incorporated herein by reference in their entireties.

Generally, there is a demand for such machines with a high degree ofaccuracy, high reliability and durability, substantial ease of use, andlow cost, among other qualities. The disclosure herein providesimprovements of at least some of these qualities.

SUMMARY OF THE INVENTIONS

In one embodiment, an articulated arm CMM comprises a plurality oftransfer members, a plurality of articulation members connecting atleast two transfer members to each other, a coordinate acquisitionmember at a distal end, and a base at a proximal end. At least two ofthe articulation members can include at least one encoder and the atleast two encoders can both be enclosed within a single monoblockhousing.

In an additional embodiment, an articulated arm CMM comprises anarticulated arm and a gas spring counterbalance. The articulated arm caninclude a plurality of articulated arm members, a coordinate acquisitionmember at a distal end, and a base at a proximal end. The gas springcounterbalance can support the arm at a rotational point betweenadjacent articulated arm members. Further, the gas spring counterbalancecan connect to an articulated arm member closer to the base at a pointnearer to the rotation point than to the base.

In yet another embodiment, an articulated arm CMM comprises anarticulated arm and a gas spring counterbalance. The articulated arm cancomprise a plurality of articulated arm members, a coordinateacquisition member at a distal end, and a base at a proximal end. Thegas spring counterbalance can support the arm at a rotational pointbetween two adjacent articulated arm members. Further, rotation at therotational point can bring one of the two adjacent articulated armmembers to a substantially horizontal position when the gas springcounterbalance is also brought to a substantially horizontal position.

In a further embodiment, an articulated arm CMM comprises an articulatedarm and a handle. The articulated arm can include a plurality ofarticulated arm members, a coordinate acquisition member at a distalend, and a base at a proximal end. The handle can include electronicsand be removable connected to the coordinate acquisition member.

BRIEF DESCRIPTION OF THE DRAWINGS

Further objects, features and advantages of the invention will becomeapparent from the following detailed description taken in conjunctionwith the accompanying figures showing illustrative embodiments of theinvention, in which:

FIG. 1 is a perspective view of an articulated arm;

FIG. 1A is an exploded view of the articulated arm of FIG. 1;

FIG. 2 is a perspective view of a transfer member of the articulated armof FIG. 1 with its associated articulation members;

FIG. 2A is a perspective view of the transfer member of FIG. 2 with acover portion removed;

FIG. 2B is an enlarged perspective view of the transfer member of FIG.2A;

FIG. 2C is an enlarged cross-sectional view of the articulation membersof FIG. 2

FIG. 2D is an enlarged cross-sectional view of the transfer member ofFIG. 2B;

FIG. 2E is a partially exploded side view of the transfer member andarticulation members of FIG. 2;

FIG. 3 is a perspective view of a counterbalance system of thearticulated arm of FIG. 1;

FIG. 3A is an exploded view of the counterbalance system of FIG. 3;

FIG. 3B is a side view of the counterbalance system of FIG. 3 in a firstposition;

FIG. 3C is a side view of the counterbalance system of FIG. 3 in asecond position;

FIG. 4 is a perspective view of a handle of the articulated arm of FIG.1;

FIG. 5 is a perspective view of a base and a feature pack of thearticulated arm of FIG. 1;

FIG. 6 is a plan view of a demonstrative embodiment of an encoder;

FIG. 7 is a screen shot from an embodiment of calibration softwareassociated with an articulated arm;

FIG. 7A is a perspective view of an articulated arm in wirelesscommunication with a computer; and

FIG. 8 is a flow diagram of a method of operating an articulated arm.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIGS. 1 and 1A illustrate one embodiment of a portable coordinatemeasuring machine (PCMM) 1 in accordance with the present invention. Inthe illustrated embodiment, the PCMM 1 comprises a base 10, a pluralityof rigid transfer members 20, a coordinate acquisition member 50 and aplurality of articulation members 30-36 that form “joint assemblies”connecting the rigid transfer members 20 to one another. Thearticulation members 30-36 along with the transfer members 20 and hinges(described below) are configured to impart one or more rotational and/orangular degrees of freedom. Through the various members 30-36, 20, thePCMM 1 can be aligned in various spatial orientations thereby allowingfine positioning and orientating of the coordinate acquisition member 50in three dimensional space.

The position of the rigid transfer members 20 and the coordinateacquisition member 50 may be adjusted using manual, robotic,semi-robotic and/or any other adjustment method. In one embodiment, thePCMM 1, through the various articulation members 30-36, is provided withseven rotary axes of movement. It will be appreciated, however, thatthere is no strict limitation to the number of axes of movement that maybe used, and fewer or additional axes of movement may be incorporatedinto the PCMM design.

In the embodiment PCMM 1 illustrated in FIG. 1, the articulation members30-36 can be divided into two functional groupings based on theirassociated motion members operation, namely: 1) those articulationmembers 30, 32, 34, 36 which are associated with the swiveling motionassociated with a specific and distinct transfer member (hereinafter,“swiveling joints”), and 2) those articulation members 31, 33, 35 whichallow a change in the relative angle formed between two adjacent membersor between the coordinate acquisition member 30 and its adjacent member(hereinafter, “hinge joints” or “hinges”). While the illustratedembodiment includes four swiveling joints and three hinge jointspositioned as to create seven axes of movement, it is contemplated thatin other embodiments, the number of and location of hinge joints andswiveling joints can be varied to achieve different movementcharacteristics in a PCMM. For example, a substantially similar devicewith six axes of movement could simply lack the swivel joint 30 betweenthe coordinate acquisition member 50 and the adjacent articulationmember 20. In still other embodiments, the swiveling joints and hingejoints can be combined and/or used in different combinations.

As is know in the art (see e.g., U.S. Pat. No. 5,829,148, which ishereby incorporated by reference herein) and depicted in FIG. 2D, thetransfer members 20 can comprise a pair of dual concentric tubularstructures having an inner tubular shaft 20 a rotatably mountedcoaxially within an outer tubular sheath 20 b through a first bearingmounted proximately to a first end of the member adjacent and a secondbearing located at an opposite end of the member and which can bepositioned within the dual axis housing 100. The transfer members 20operate to transfer motion from one end of the transfer member to theother end of the transfer member. The transfer members 20 are, in turn,connected together with articulation members 30-36 to form jointassemblies.

The hinge joint, in turn, is formed, in part, by the combination of ayoke 28 extending from one end of a transfer member (see FIG. 1A), therotational shaft extending through the articulation members 31, 33, 35and the articulation members 31, 33, 35 themselves, which rotate aboutthe rotational shaft to form a hinge or hinge joint.

Each hinge or swiveling joint has its own dedicated motion transducer inthe form of an encoder 37 which can be seen in FIG. 2C. Advantageously,both the hinge and swiveling joint encoders are positioned at leastpartially, and more preferably, entirely within the dual axis housing100 within the respective articulation members 30-36.

In various embodiments, the coordinate acquisition member 50 comprises acontact sensitive member 55 (depicted as a hard probe in FIG. 1)configured to engage the surfaces of a selected object and generatecoordinate data on the basis of probe contact. In the illustratedembodiment, the coordinate acquisition member 50 also comprises anon-contact scanning and detection component that does not necessarilyrequire direct contact with the selected object to acquire geometrydata. As depicted, the non-contact scanning device comprises anon-contact coordinate detection device (shown as a laser coordinatedetection device/laser scanner) that may be used to obtain geometry datawithout direct object contact. The non-contact scanning device caninclude a camera or other optical device 70, which functions inconjunction with a laser not depicted herein. It will be appreciatedthat various coordinate acquisition member configurations including: acontact-sensitive probe, a non-contact scanning device, a laser-scanningdevice, a probe that uses a strain gauge for contact detection, a probethat uses a pressure sensor for contact detection, a device that uses aninfrared beam for positioning, and a probe configured to beelectrostatically-responsive may be used for the purposes of coordinateacquisition. Further, in some embodiments, a coordinate acquisitionmember 50 can include one, two, three, or more than three coordinateacquisition mechanisms.

Further description of certain embodiments of a coordinate acquisitionmember that can be used with the embodiments described herein can befound in U.S. patent application Ser. No. 12/487,535, filed 18 Jun. 2009and entitled ARTICULATING MEASURING ARM WITH LASER SCANNER, now issuedas U.S. Pat. No. 7,908,757, which is incorporated by reference herein inits entirety. As depicted in said reference, the coordinate acquisitionmember can include a modular laser scanner that can attach to the mainbody of the coordinate acquisition member (which can also include atouch probe). The modular features can allow various other coordinatedetection devices to be used with the coordinate acquisition member.Additionally, other coordinate acquisition members can be used, as isgenerally know by those of skill in the art.

Advantageously, as depicted in FIGS. 2-2C, the articulation members30-36 form a dual-axis housing 100. The dual-axis housing 100 can be asingle monoblock housing, a housing comprising multiple pieces bondedtogether (e.g. by welding, adhesive, etc.), or otherwise. As depicted,the dual-axis housing 100 can be coupled to the transfer members 20 andcomprise part of hinge and swivel joints, corresponding to the secondand third axes of rotation from the base 10. As noted above, separatelyfunctional rotational encoders 37 and associated electronics formeasuring a position of the transfer members and hinge and swivel joints(as are generally known by those of skill in the art) can be positionedin the articulation members 34 and 35 (as well as the articulationmembers 30-33 and 36, depicted in other figures).

To facilitate assembly of the dual-axis assembly, the dual-axis housing100 can include a removable back cover 102, shown removed in FIG. 2A. Asdepicted, the removable cover 102 can cover an opening in the housing100 generally axially aligned with an adjacent transfer member 20mounted to the housing. Further, in some embodiments the cover 102 canbe configured so as not to bare any significant load of the CMM 1.Accordingly, it may be desirable to form the cover 102 of a less rigidmaterial that can also serve as a shock absorber. As depicted, the cover102 can be positioned at an “elbow” position of the arm 1. During someactivities the “elbow” positions may be more likely to abruptly contactan external, hard surface that could damage the arm 1. Advantageously, acover 102 formed of a shock absorbent material can protect the arm 1from such damage. Even further, in some embodiments the material of thecover 102 can also serve to promote enhanced sealing with the materialof the dual-axis housing 100. The dual-axis housing 100 can comprise arigid material, and the cover 102 can comprise a more flexible materialthat can conform to the edges of the housing when mounted thereto,creating an enhanced seal.

The removable back cover 102 can provide a general sealing of theinterior of the dual-axis housing 100 from the external elements,protecting the encoders 37 positioned within the housing. When the cover102 is removed the separate encoder 37 associated with the articulationmember 34 can be exposed and inserted/removed from the dual-axis housing100 into a swivel-receiving portion 104 generally axially aligned withthe depicted transfer member 20 (as depicted in FIG. 2E). In theillustrated embodiment, the encoders associated with the articulationmembers 34 and 35 are separate components from the transfer members 20.That is, the encoder and transfer member are two separate and distinctcomponents that are connected together but can rotatably operate apartfrom each other. The same principle can also be applied to the otherarticulation members 30-33 and 36. That is, the transfer members 20 canoperate separately from the articulation members 30-36 that form a jointor joint assembly as described above and operate to measure rotation.

Additionally, additional electronics can be inserted/removed while thecover 102 is removed, as depicted in FIG. 2B. As shown, the dual-axishousing 100 can provide a receiving portion for a printed circuit board38 that can hold additional electronics. In some embodiments, theadditional electronics can perform additional signal processing such asdigitizing an analog signal from the encoders. In some embodiments, suchdigitization can be performed prior to passing the signal to slip ringsor other rotatable electronic connections. Further, in some embodimentsthe additional printed circuit board 38 can facilitate forming thephysical electronic connection between both encoders within thedual-axis housing 100.

Further, in the depicted dual-axis housing 100 the separate encoder 37associated with the articulation member 35 can be inserted/removedindependent of the back cover 102. To facilitate this insertion/removal,the dual-axis housing 100 can have a hinge-receiving portion 106oriented perpendicularly from a primary plane of the housing. Thehinge-receiving portion 106 can have an open end 108, into which theencoder 37 can enter, and a substantially closed end 110 against whichthe encoder can abut to define a position for the encoder. Once theencoder 37 has been inserted, a cap piece 112 can then be inserted tosecure the encoder within the hinge-receiving portion 106.

As depicted in FIG. 2C, the encoder 37 can include an encoder disk 38 aand a read head 38 b. The encoder disk 38 a can have a pattern on itssurface that can be measured by the read head 38 b. For example, in someembodiments the encoder disk 38 a can have an optical pattern includingvarying colors, transparent and opaque portions, or other visiblevariations; and the read head 38 b can include an optical measuringdevice such as a camera. In some embodiments the disk 38 a can have adefined pattern of lines on the disk similar to a bar code such that anyimage of the disk by the read head can define an absolute rotationalangle, as further discussed below. As another example, the encoder disk38 a can have varying magnetic portions and the read head 38 b canmeasure a corresponding magnetic field. The varying patterns on theencoder disk 38 a can be measured by the read head 38 b to indicate arotational position, or a change in rotational position of the encoderdisk relative to the read head. In turn, as depicted, the read head 38 bcan be rotationally fixed with the housing 100 and the encoder disk 38 acan be rotationally fixed to an encoder shaft 39 that is rotatablymounted within the housing. Thus, rotation of the shaft 39 relative tothe housing 100 can cause a corresponding relative rotation between thedisk 38 a and read head 38 b that can be measured. However, it will beclear from the description herein that the apparatus can vary. Forexample, in some embodiments the read head 38 b can be rotatably mountedto the housing 100 and the encoder disk 38 a can be rotatably fixed.

In the depicted embodiment, the encoder associated with the articulationmember 35 can mount with an adjacent transfer member, not shown in FIG.2, via a fork joint on the transfer member and the encoder shaft 39.Said fork joint can be similar to that depicted at the end of thedepicted transfer member 20 opposite the dual-axis housing 100, with ayoke 28 that can mount to the encoder shaft 39 rotatably mounted withinthe housing 100. The forks of the yoke 28 can mount about the ends ofthe dual-axis housing 100 and its contained encoder to form a hingearticulation member 35. Accordingly, both encoders in the dual-axishousing 100 can be inserted/removed independently of one another fromthe single housing. Notably, in other embodiments the form of thedual-axis housing 100 can vary. For example, in some embodiments thedual-axis housing 100 can form two swivel-receiving portions 104, or twohinge-receiving portions 106, as opposed to one of each.

Placing the encoders 37 into a single housing can provide numerousadvantages over prior art assemblies with separate housings. Forexample, the combined housing can reduce the number of parts and jointsrequired, and thus also reduce cost and assembly time. Further, theaccuracy of the device can improve from the elimination of deflection,misalignment, or other problems with multiple components. Additionally,removal of the additional housing can allow a more compact combinedjoint assembly, allowing the arm to be better supported and have lessweight. As shown FIG. 1A, a yoke 28 of the next or proceeding transfermember 20 can be coupled to the bearing shaft extending through dualaxis housing 100 to form the hinge joint.

Although depicted as enclosing the second and third axes from the base,a similar dual-axis housing 100 can be used with other combinations ofarticulation members, such as the fourth and fifth articulation members32, 33. Further, the dual-axis housing can provide additional advantagesnot explicitly discussed herein. However, it should be noted that inother embodiments of the inventions described herein, the articulationmembers 30-36 can each have a separate housing.

It should be appreciated that the dual-axis housing or joint assemblydescribed above can be used in other types of CMMs and need not be usedin combination with the additional embodiments described below.

FIGS. 3 and 3A depict an improved counterbalance system 80. As depicted,the counter balance system 80 can include a piston assembly 84 forming agas shock counterbalance. A nitrogen charged gas spring can connectbetween points separated by a pivot 88 aligned with an articulationmember such as the second-closest-to-the-base articulation member 35. Asdepicted, the connection point nearer the base 10 can be closer to thepivot 88 than to the base. This results in a counterbalance design wherethe gas shock is in a predominantly horizontal position when the secondlinkage is in a horizontal position, as depicted in FIG. 3C. Thepredominantly horizontal position of the gas shock can be furtherpromoted by the position of the connection point further from the base.As depicted, the connection point further from the base can bepositioned at approximately the mid-point of the transfer member 20supported by the counterbalance system 80. Further, as depicted thepiston assembly 84 can include a lock 86 that can increase theresistance against movement of the piston, thus preventing additionalrotation of the aligned articulation member 35. In one embodiment thelock is implemented with a lever on the lock 86, pushing on a pin thatopens and closes an aperture within the gas shock. The opening andclosing of the aperture either allows or prevents the flow of gas withinthe piston.

This improved counterbalance system 80 can provide a number ofadvantages. For example, this design can allow the first axis ofrotation from the base (associated with articulation member 36) to beshorter, reducing associated deflection. Additionally, this reducedlength can be accomplished without a reduced angular span of rotationabout the pivot 88. The improved counterbalance system 80 can alsoreduce the number of parts required, as the locking mechanism and thecounterbalance mechanism can be integrally combined into a singlesystem. Further, the piston assembly 84 can damp the motion about thepivot 88. This reduces the chance of damaging the CMM when a user triesto move the arm while it is still locked. However, it should be notedthat in other embodiments of the inventions described herein, adifferent counterbalance system can be used, such as a weight providedon a back end of a transfer member 20. Further, in other embodiments ofthe inventions described herein, a different locking mechanism can beused, such as a rigid physical stop. It should be appreciated theimproved counterbalance system 80 described above can be used in othertypes of CMMs and need not be used in combination with the additionalembodiments described above and below the preceding section.

FIG. 4 depicts an improved handle 40. The handle 40 can include one ormore integrated buttons 41. The handle can connect to the axis withbolts, snaps, or clamps. Additionally, the handle 40 can includeelectronics 44 included within its interior. Advantageously, providingthe electronics 44 in the handle 40 can further separate the electronicsfrom rotational encoders and other components that may lose accuracywhen heated. In some embodiments the handle 40, or the electronics 44therein, can be thermally isolated from the remainder of the arm.Additionally, when the handle 40 is removable and includes theelectronics 44, it can form a modular component similar to the featurepacks (described below). Thus, a user can change the functionality bychanging the handle 40, and accordingly also changing the electronics 44and the buttons 41 that control the electronics. A plurality of handles40 with different functionalities can thus be provided in a CMM systemto provide modular features to the CMM. Again, it should be noted thatin other embodiments of the inventions described herein, a differenthandle can be used, or alternatively there can be no distinct handle.Additionally, the handle can contain a battery to power the arm, thescanner or both.

It should be appreciated the improved handle 40 described above can beused in other types of CMMs and need not be used in combination with theadditional embodiments described above and below the preceding section

Additionally or alternatively, in some embodiments a CMM arm 1 can be atleast partially controlled by motion of the arm itself, as depicted inFIG. 8. For example, whereas some commands or instructions may betriggered by the pressing of a button, pulling a lever, turning a dial,or actuating some other traditional actuation device in someembodiments, in other embodiments the same or different instruction canbe triggered by a specific motion or position of the CMM arm 1, whichcan be detected by the encoders 37. As a more specific example, in someembodiments the CMM arm 1 can be instructed to enter a sleep mode whenthe arm is placed in a generally folded or retracted position, such asthat depicted in FIG. 1. The CMM arm 1 can then perform thatinstruction. Similarly, the CMM arm 1 can be reawakened by a rapidmovement, or movement into a more extended position. Other combinationsof instructions, motions, and positions are possible.

For example, in some embodiments the CMM arm 1 can enter into differentdata acquisition modes depending on its general orientation. Varying thedata acquisition mode by position can be advantageous where the CMM arm1 regularly measures products that require different data acquisitionmodes along different parts of a product.

Further, in some embodiments the arm can enter into different dataacquisition modes depending on its speed of movement. For example, anoperator of the CMM may move the CMM slowly when a critical point willsoon be measured. Thus, the CMM can increase its measurement frequency,accuracy, or other characteristics when the arm is moving slowly.Additionally, the CMM can be toggled between a mode where the arm isused as a computer mouse and a measurement mode with a quick movement ofone of the last axes (embodiments of an associated computer furtherdescribed below).

As with the previous embodiments, it should be appreciated that thesefeatures related to control of the arm can be used in other types ofCMMs and need not be used in combination with the additional embodimentsdescribed above and below the preceding section.

FIG. 5 depicts a set of feature packs 90 that can connect with the base10 via a docking portion 12. The docking portion 12 can form anelectronic connection between the CMM arm 1 and the feature pack 90. Insome embodiments the docking portion 12 can provide connectivity forhigh-speed data transfer, power transmission, mechanical support, andthe like. Thus, when connected to a docking portion, a feature pack 90can provide a modular electronic, mechanical, or thermal component tothe CMM arm 1, allowing a variety of different features andfunctionality such as increased battery life, wireless capability, datastorage, improved data processing, processing of scanner data signals,temperature control, mechanical support or ballast, or other features.In some embodiments this modular functionality can complement or replacesome modular features of the handle 40. The modular feature packs cancontain connectors for enhanced functionality, batteries, electroniccircuit boards, switches, buttons, lights, wireless or wiredcommunication electronics, speakers, microphones, or any other type ofextended functionality that might not be included on a base levelproduct. Further, in some embodiments the feature packs 90 can bepositioned at different portions of the CMM arm 1, such as along atransfer member, an articulation member, or as an add-on to the handle40.

As one example, a feature pack 90 can include a battery, such as aprimary battery or an auxiliary battery. Advantageously, in embodimentswhere the pack 90 is an auxiliary battery the CMM can include aninternal, primary battery that can sustain operation of the CMM whilethe auxiliary battery is absent or being replaced. Thus, by circulatingauxiliary batteries a CMM can be sustained indefinitely with no directpower connection.

As another example, a feature pack 90 can include a data storage device.The available data storage on the feature pack 90 can be arbitrarilylarge, such that the CMM can measure and retain a large amount of datawithout requiring a connection to a larger and/or less convenient datastorage device such as a desktop computer. Further, in some embodimentsthe data storage device can transfer data to the arm, includinginstructions for arm operation such as a path of movement for amotorized arm, new commands for the arm upon pressing of particularbuttons or upon particular motions or positions of the arm, or othercustomizable settings.

In examples where the feature pack includes wireless capability, similarfunctionality can be provided as with a data storage device. Withwireless capability, data can be transferred between the CMM and anexternal device, such as a desktop computer, continuously without awired connection. In some embodiments, the CMM can continuously receivecommands from the auxiliary device. Further, in some embodiments theauxiliary device can continuously display data from the arm, such as thearm's position or data points that have been acquired. In someembodiments the device can be a personal computer (“PC”) and the featurepack can transmit arm coordinate data and scanner data wirelessly to thePC. Said feature pack can combine the arm data and scanner data in thefeature pack before wireless transmission or transmit them as separatedata streams.

In further embodiments, the feature packs can also include dataprocessing devices. These can advantageously perform various operationsthat can improve the operation of the arm, data storage, or otherfunctionalities. For example, in some embodiments commands to the armbased on arm position can be processed through the feature pack. Inadditional embodiments, the feature pack can compress data from the armprior to storage or transmission.

In another example, the feature pack can also provide mechanical supportto the CMM. For example, the feature pack can connect to the base 10 andhave a substantial weight, thus stabilizing the CMM. In otherembodiments, the feature pack may provide for a mechanical connectionbetween the CMM and a support on which the CMM is mounted.

In yet another example, the feature pack can include thermalfunctionality. For example, the feature pack can include a heat sink,cooling fans, or the like. A connection between the docking portion andthe feature pack can also connect by thermally conductive members toelectronics in the base 10 and the remainder of the CMM, allowingsubstantial heat transfer between the CMM arm and the feature pack.

Further, as depicted in FIG. 1, in some embodiments the feature packs 90can have a size and shape substantially matching a side of the base 10to which they connect. Thus, the feature pack 90 can be used withoutsubstantially increasing the size of the CMM, reducing its possibleportability, or limiting its location relative to other devices.

Again, the feature packs 90 can be used in combination with each otherand the other features described herein and/or can be used independentlyin other types of CMMs.

Additionally, in some embodiments the CMM arm 1 can include an absoluteencoder disk 95, a demonstrative embodiment depicted in FIG. 6. Theabsolute encoder disk 95 can include a generally circular, serializedpattern that can be embodied in reflective and non-reflective materials,translucent and non-translucent materials, alternating magneticproperties, or the like. The serialized pattern can allow a read head todetermine a unique position on the encoder by only reading a limitedportion of the encoder's coded surface. In some embodiments, theserialized pattern can resemble a bar code, as depicted in FIG. 6. Thepattern can be non-repetitive along a viewing range of an associatedread-head. Thus, an image or other data collected by the read-head fromthe encoder disk 95 can yield a pattern unique from any other positionon the encoder, and therefore be associated with a unique angularposition. Each encoder can consist of a single serialized disk that isread by one or more read-heads that can be, e.g., CCD imagers. The useof two or preferably four CCD imagers can improve the accuracy of theencoder by measuring the eccentricity of the axis and subtracting outthe eccentricity from the angle measurement. Further, the angle accuracycan be improved by averaging the measurements of the multiple CCDimagers.

In prior art encoders an incremental and repetitive surface was oftenused, in which the coded surface only indicates incremental steps andnot an absolute position. Thus, incremental encoders would require areturn to a uniquely identified home position to re-index and determinethe incremental positions away from the home position. Advantageously,some embodiments of an absolute encoder disk 95 can eliminate therequired return to a home position. This feature of a CMM can also beused in combination with the other features described herein and/or canbe used independently in other types of CMMs.

Advantageously, the absolute encoder disk 95 can improve functionalityof a CMM arm 1 that enters a sleep mode. Entering sleep mode can reducethe power consumption of a CMM arm 1. However, if enough systems areshut down during sleep mode then incremental encoders may “forget” theirposition. Thus, upon exiting sleep mode incremental encoders may need tobe brought back to the home position prior to use. Alternatively,incremental encoders can be kept partially powered-on during sleep modeto maintain their incremental position. Advantageously, with an absoluteencoder disk 95 the encoders can be completely powered off during sleepmode and instantly output their position when power is returned. Inother modes, the absolute encoder can read its position at a lowerfrequency without concern that it may miss an incremental movement andthus lose track of its incremental position. Thus, the CMM arm 1 can bepowered-on or awakened and can immediately begin data acquisition, fromany starting position, without requiring an intermediary resetting tothe “home” position. In some embodiments absolute encoders can be usedwith every measured axis of rotation of the CMM. This feature of a CMMcan also be used in combination with the other features described hereinand/or can be used independently in other types of CMMs. For example, asdescribed above, this sleep mode can be induced by movement into aparticular position. As a further example, the encoder disk 38 a can bean absolute encoder disk 95.

Additionally, in some embodiments the CMM arm 1 can be associated withcalibration software. Generally, calibration of a CMM arm can beperformed by positioning the distal end of the CMM arm (e.g. the probe)at certain predefined and known positions, and then measuring theangular position of the arm. However, these calibration points often donot define a unique arm orientation, but instead can be reached with aplurality of arm positions. To improve the effectiveness of thecalibration procedure, software can be included that indicates apreferred or desired CMM arm calibration position la, including thedistal point as well as the orientation of the rest of the arm. Further,in some embodiments the software can also show the arm's currentposition 1 b in real time as compared to the desired position 1 a, asdepicted in FIG. 7. Even further, in some embodiments the software canhighlight portions of the arm that are out of alignment with the desiredposition 1 a.

As depicted in FIG. 7A, the calibration software can be included on aseparate, auxiliary device such as a computer 210 coupled to a display220 and one or more input devices 230. An operator 240 may plan acalibration procedure using system the computer 210 by manipulating theone or more input devices 230, which may be a keyboard and/or a mouse.The display 220 may include one or more display regions or portions,each of which displays a different view of the CMM arm 1 in its currentposition, and optionally a desired calibration position (as describedabove). Each of these displays may be linked internally within a programand data on computer 210. For example, a program running on a computer210 may have a single internal representation of the CMM arm's currentposition in memory and the internal representation may be displayed intwo or more abstract or semi-realistic manners on display 220.

In various embodiments, the computer 210 may include one or moreprocessors, one or more memories, and one or more communicationmechanisms. In some embodiments, more than one computer may be used toexecute the modules, methods, and processes discussed herein.Additionally, the modules and processes herein may each run on one ormultiple processors, on one or more computers; or the modules herein mayrun on dedicated hardware. The input devices 230 may include one or morekeyboards (one-handed or two-handed), mice, touch screens, voicecommands and associated hardware, gesture recognition, or any othermeans of providing communication between the operator 240 and thecomputer 210. The display 220 may be a 2D or 3D display and may be basedon any technology, such as LCD, CRT, plasma, projection, et cetera.

The communication among the various components of system 200 may beaccomplished via any appropriate coupling, including USB, VGA cables,coaxial cables, FireWire, serial cables, parallel cables, SCSI cables,IDE cables, SATA cables, wireless based on 802.11 or Bluetooth, or anyother wired or wireless connection(s). One or more of the components insystem 200 may also be combined into a single unit or module. In someembodiments, all of the electronic components of system 200 are includedin a single physical unit or module.

The enhanced capabilities of the calibration software can allow theoperator to refer simply to the live images on the display and positionthe live image over the desired image which reduces the need for manualsor additional training documentation which slows down the calibrationprocess. Additionally, new calibration technicians can be trainedaccurately and quickly with the aid of the aforementioned display. Thedata acquired from these methods of calibration can be more repeatableand more accurate due to, e.g., increased consistency of articulations.In addition to positioning of the CMM in the correct pose, thecalibration artifact 120 should be positioned in the correct locationwithin the arm's volume of reach. When the display shows a true 3dimensional image, the position of the calibration artifact in 3D spacecan also be correctly displayed, further ensuring that the correctvolume of measurement is measured.

These calibration features of a CMM can also be used in combination withthe other features described herein and/or can be used independently inother types of CMMs. For example, in some embodiments the calibrationprocess can utilize commands based on the position and motion of the CMM(as discussed above). In some embodiments, during calibration holdingthe arm still for an extended period of time can indicate to thecalibration software that the arm is in the desired position. Thesoftware can then acknowledge its processing of this command with achange in display, sound, color, etc. This result can then be confirmedby the operator with a rapid motion of the arm out of said position. Thecalibration software can then indicate a next calibration point, orindicate that calibration is complete. In addition this functionalitycan be extended to the operator as well. One example is during thecalibration of the probe the software can display the requiredarticulation pose that the CMM should be in as well as the actual posethat it is in. The operator can then move the CMM until it is in thecorrect position and record a position or it can be recordedautomatically. This simplifies the process for the user and improves theaccuracy of the data taken. Different methods can be presented dependingon the type of probe that is sensed to be present such as laser linescanner, touch trigger probe, etc.

Even further, in some embodiments the CMM arm 1 can include a tiltsensor. In some embodiments the tilt sensor can have an accuracy of atleast approximately 1 arc-second. The tilt sensor can be included in thebase 10, a feature pack 90, or in other parts of the CMM arm 1. Whenplaced in the base 10 or the feature pack 90, the tilt sensor can detectmovement of the CMM arm's support structure, such as a table or tripodon which the arm sits. This data can then be transferred to processingmodules elsewhere in the arm or to an external device such as acomputer. The CMM arm 1 or the external device can then warn the user ofthe movement in the base and/or attempt to compensate for the movement,for example when the tilt changes beyond a threshold amount. Warnings tothe user can come in a variety of forms, such as sounds, LED lights onthe handle 40 or generally near the end of the arm 1, or on a monitorconnected to the arm 1. Alternatively or additionally, the warning canbe in the form of a flag on the data collected by the arm 1 when tiltinghas occurred. This data can then be considered less accurate whenanalyzed later. When attempting to compensate for the movement, in someembodiments the tilting and its effects on position can be partiallymeasured and accounted for in the calibration process. In furtherembodiments, the tilting can be compensated by adjusting the angularpositions of the articulation members accordingly. This feature of a CMMcan also be used in combination with the other features described hereinand/or can be used independently in other types of CMMs.

In further embodiments, a trigger signal is sent from the arm to thescanner upon each measurement of the arm position. Coincident with thearm trigger the arm can latch the arm position and orientation. Thescanner can also record the time of receipt of the signal (e.g. as atime stamp), relative to the stream of scanner images being captured(also, e.g., recorded as a time stamp). This time signal data from thearm can be included with the image data. Dependent on the relativefrequency of the two systems (arm and scanner) there may be more thanone arm trigger signal per scanner image. It might not be desirable tohave the arm running at a lower frequency than the scanner, and thisusually results in the arm and scanner frequencies being at leastpartially non-synchronized. Post-processing of the arm and scanner datacan thus combine the arm positions by interpolation with the scannerframes to estimate the arm position at the time of a scanner image. Insome embodiments, the interpolation can be a simple, linearinterpolation between the two adjacent points. However, in otherembodiments higher-order polynomial interpolations can be used toaccount for accelerations, jerks, etc. This feature of a CMM can also beused in combination with the other features described herein and/or canbe used independently in other types of CMMs.

The various devices, methods, procedures, and techniques described aboveprovide a number of ways to carry out the invention. Of course, it is tobe understood that not necessarily all objectives or advantagesdescribed may be achieved in accordance with any particular embodimentdescribed herein. Also, although the invention has been disclosed in thecontext of certain embodiments and examples, it will be understood bythose skilled in the art that the invention extends beyond thespecifically disclosed embodiments to other alternative embodimentsand/or uses and obvious modifications and equivalents thereof.Accordingly, the invention is not intended to be limited by the specificdisclosures of preferred embodiments herein.

What is claimed is:
 1. An articulated arm CMM system comprising: anarticulated arm comprising a plurality of articulated arm members, acoordinate acquisition member at a distal end, a base at a proximal end,and a single docking portion substantially at the coordinate acquisitionmember; and two or more modular handles comprising electronics andconfigured to be removably connected to the articulated arm at thesingle docking portion, wherein a first modular handle provides a firstadditional electronic feature or functionality and a second modularhandle provides a second additional electronic feature or functionalitydistinct from the first additional electronic feature or functionalityto the articulated arm.
 2. The articulated arm CMM system of claim 1,wherein the electronics are thermally isolated from the articulated arm.3. The articulated arm CMM system of claim 1, wherein the handles arethermally isolated from the articulated arm when removable connected tothe articulated arm at the single docking portion.
 4. The articulatedarm CMM system of claim 1, wherein at least one modular handle comprisesa data storage device.
 5. The articulated arm CMM system of claim 4,wherein at least one modular handle comprises instructions for armoperation.
 6. The articulated arm CMM system of claim 1, wherein atleast one modular handle comprises a wireless capability for datatransfer.
 7. The articulated arm CMM system of claim 1, wherein at leastone modular handle comprises a battery.
 8. An articulated arm CMM systemcomprising: an articulated arm comprising a plurality of articulated armmembers, a coordinate acquisition member at a distal end, a base at aproximal end, and a single docking portion substantially at thecoordinate acquisition member; and a modular handle comprisingelectronics and removably connected to the articulated arm at the singledocking portion, the modular handle being capable of providing modularfunctionality, wherein the articulated arm is configured to measure andoutput a position of an end of the articulated arm.
 9. The articulatedarm CMM system of claim 8, wherein the modular handle provides saidmodular functionality through the single docking portion.
 10. Thearticulated arm CMM of system claim 8, wherein the electronics arethermally isolated from the articulated arm.
 11. The articulated arm CMMsystem of claim 8, the handle is thermally isolated from the articulatedarm.
 12. The articulated arm CMM system of claim 8, wherein the handlecomprises a data storage device.
 13. The articulated arm CMM system ofclaim 12, wherein the handle comprises instructions for arm operation.14. The articulated arm CMM system of claim 8, wherein the handlecomprises a wireless capability for data transfer.
 15. The articulatedarm CMM system of claim 8, wherein the handle comprises a battery. 16.An articulated arm CMM comprising: an articulated arm comprising aplurality of articulated arm members, a coordinate acquisition member ata distal end, a base at a proximal end, and a single docking portionsubstantially at the coordinate acquisition member, wherein the dockingportion is configured to form a connection with a modular handlecomprising electronics and removably connected to the articulated arm atthe single docking portion, the modular handle being capable ofproviding modular functionality, and wherein the articulated arm isconfigured to measure and output a position of an end of the articulatedarm.
 17. The articulated arm CMM of claim 16, wherein the articulatedarm is configured to measure and output a position of an end of thearticulated arm with or without a modular handle connected.
 18. Thearticulated arm CMM of claim 17, wherein the articulated arm isconfigured to receive instructions through the docking portion.
 19. Thearticulated arm CMM of claim 16, wherein the docking portion isconfigured to thermally isolate the modular handle from the articulatedarm CMM.
 20. The articulated arm CMM of claim 16, wherein the dockingportion is configured to form a data connection.
 21. The articulated armCMM of claim 16, wherein the articulated arm is configured to receivepower through the docking portion.
 22. A modular handle for anarticulated arm CMM system comprising a modular design and electronics,the modular handle being configured to removably attach to thearticulated arm CMM system, and further being configured to provide anadditional electronic feature or functionality to the articulated armCMM.
 23. The modular handle of claim 22, wherein the electronics areconfigured to be thermally isolated from the articulated arm CMM systemby the modular handle.
 24. The modular handle of claim 22, wherein thehandle further comprises a data storage device.
 25. The modular handleof claim 24, wherein the handle comprises instructions for armoperation.
 26. The modular handle of claim 22, wherein the handlecomprises a wireless capability for data transfer.
 27. The modularhandle of claim 22, wherein the handle comprises a battery.
 28. Themodular handle of claim 22, wherein the modular handle is configured toremovably attach to the articulated arm CMM system with bolts.
 29. Themodular handle of claim 22, wherein the modular handle is configured toremovably attach to the articulated arm CMM system with snaps.
 30. Themodular handle of claim 22, wherein the modular handle is configured toremovably attach to the articulated arm CMM system with clamps.
 31. Amethod of providing modular functionality to an articulated arm CMMcomprising: attaching a first modular handle to an articulated arm CMMat a docking portion to provide a first additional feature orfunctionality to the articulated arm CMM; measuring one or morecoordinates with the articulated arm CMM and utilizing the firstadditional feature or functionality; replacing the first modular handlewith a second modular handle at the docking portion to provide a secondadditional feature or functionality to the articulated arm CMM; andmeasuring one or more coordinates with the articulated arm CMM andutilizing the second additional feature or functionality.
 32. The methodof claim 31, further comprising the step of measuring one or morecoordinates with the articulated arm CMM while no modular handle isattached to the articulated arm CMM.
 33. The method of claim 31, whereinthe step of replacing is done while the articulated arm CMM is still inuse.
 34. The method of claim 31, wherein the step of attaching isperformed with bolts.
 35. The method of claim 31, wherein the step ofattaching is performed with snaps.
 36. The method of claim 31, whereinthe step of attaching is performed with clamps.
 37. The method of claim31, wherein at least one of the modular handles comprises electronicsconfigured to be thermally isolated from the articulated arm CMM systemby the modular handle.
 38. The method of claim 31, wherein the modularhandles are configured to be thermally isolated from the articulated armCMM system by the docking portion.
 39. The method of claim 31, whereinat least one of the modular handles comprises a data storage device. 40.The method of claim 39, wherein the at least one handle comprisesinstructions for arm operation.
 41. The method of claim 31, wherein atleast one of the modular handles comprises a wireless capability fordata transfer.
 42. The method of claim 31, wherein at least one of themodular handles comprises a battery.